Cylinder Oil Drain & Engine Performance Analysis

1 Cylinder Oil Drain & Engine Performance Analysis Condition Monitoring and Maintenance Planning for 2-stroke marine diesel engines Terence MCGeary, Managing Director, Flame Marine Limited 29, The Gill, Ulverston LA12 7BP, UK. Tel: +44 1229 588601 Fax: +44 1229 587959. e-mail: Fabian Chew, Technical Director, Flame Marine Limited, , Chempang Kuning Link, Singapore 486237. Tel: +65 9677 4315 Fax: +65 6234 2754. e-mail: Fab i a n @ fl a me ma r in m The Authors Terence McGeary joined Shell Tankers in 1952 as Engineer Cadet. In 1967 he joined Chevron International as Manager Marine Lubricants & Technical Service. He was a founding partner of Flame Marine Limited in September 2000.

2 Fabian Chew joined Neptune Orient Line in 1980 as Engineer Cadet and served as Engineer Officer at sea and then as Engineer Superintendent until 1996. In September 2000 he was a founding partner of Flame Marine Limited. ABSTRACT INTRODUCTION. This paper presents the case for comparing The use of Cylinder Drain Analysis to evaluate the Cylinder lubricant Drain Analysis and Engine Performance of Cylinder lubricants is a procedure Performance data from 2- Stroke Marine Diesel familiar to the major oil companies for more than Engines in order to monitor and optimize Engine 40 years. In 1994 the authors' company reversed Performance and operation.

3 The procedure has the procedure and began using Drain Analysis to been developed by the authors over the past five investigate combustion and lubrication conditions years and requires that the Cylinder Drain oil in engines. The first conclusion of this testing in samples and fuel samples are collected 1996 was that many modern large bore 2-stroke simultaneously with the recording of Engine engines were being over-lubricated and that the Performance data. deposits from the burning of excess lubricant were causing ring seizure and liner wear. In recent It has been noted that the characteristics of the years the Engine manufacturers have revised their fuel in use and the Engine operating conditions are lubrication recommendations and now propose reflected in the Drain oil Analysis .

4 Conversely this Cylinder lubricant feed rates ranging 30% to 50%. means that information from the Cylinder Drain oil below previous recommendations. can provide an insight into the Engine conditions and confirm whether these are normal or The diagnostic procedures for studying fuel otherwise. Cylinder Drain & Engine Performance characteristics, Cylinder lubricant Drain analyses Analysis procedures detect abnormal combustion and Engine Performance have been developed or lubrication conditions providing early warning over the past three years and are now applied to of developing problems whether from incorrect over 150 ships. Sampling of fuel and Cylinder settings or component malfunction.

5 Drain oil and collection of Engine Performance data is carried out between 4 and 12 times per year, the frequency being dependent on the voyage schedule and operator requirements. By interpretation of the information collected Cylinder Lubricant Drain & Engine developing faults can be identified well before Performance Analysis they may be visible through the Performance data In the paper Study of the Relationship between or physical inspection. Evaluation of information Cylinder Lubricant Drain condition and from the Analysis also allows recommendations Performance Parameters of 2-stroke Cross-head for adjustments to fuel, lubrication and Engine Engines the case was made for the Analysis of settings, and for planning of overhaul of injectors Cylinder Lubricant Drain oil as a method for the and Cylinder units, including when overhaul determination of Engine operating conditions, the intervals can be extended.

6 The service is used to planning of Engine maintenance and setting of plan overhaul by need, rather than according to Cylinder lubricant feed rate. Engine hours, and to assist Chief Engineers and Engineer Superintendents to ensure economic and Over the past two years Cylinder oil Drain and fuel reliable Engine operation. analyses and Engine Performance data have been collected from 150 ships, and procedures Engine Performance is normally recorded when developed for scrutinizing and interpreting the ship is in loaded condition, at Engine load of approximately 500 pieces of information which 80% to 90% of Maximum Continuous Rating and are used to develop each ship report.

7 This paper in calm sea. These same conditions are also reports on the progress made since 2001 in the use required for sampling of Cylinder lubricant Drain of Cylinder Lubricant Drain & Engine oil. Performance Analysis as an important tool for obtaining a more complete understanding of By taking the Cylinder lubricant Drain samples and operating conditions in 2-stroke marine diesel sample of the fuel from the fuel pump at the same engines and for planning of Engine maintenance. time as the recording of Engine Performance , a unique snapshot is taken which enables precise comparisons to be made. For an accurate Sources of Data evaluation a full range of Engine data is required, most, or all of which is normally collected by To be able to develop a complete diagnosis of Engine room staff when recording Performance Engine operating conditions a range of data is data.

8 The introduction of digital diesel Analysis required which includes: has simplified data collection. And the provision Analysis of the fuel delivered of additional information, such as Injection Analysis of the fuel before high pressure fuel angles, Ignition angles and Mean Indicated pump Pressure (MIP) facilitates more precise diagnosis. Engine Performance data, including fuel and lubricator settings Engine Performance Diagnosis Archive from the Diesel Analyzer (if fitted). It is important that Performance data is carefully Overhaul and Cylinder calibrations data. studied and evaluated to ensure reliable and Analysis of a Cylinder Drain oil sample from economic operation of the engines.

9 However each Cylinder unit many companies leave the responsibility of evaluation of Performance Data to the The Fuel superintendents and chief engineers to interpret and act on the data. This is a duty which is The characteristics of fuel vary between becoming more difficult as superintendents are deliveries, due to changes in the crude source and/. over-loaded with work and travel, and the number or fuel source, variations in refining procedure of engineers on board ship is reduced. Engine and differing blend components, and Performance Analysis requires painstaking study contaminants. Once on board the fuel is treated by to arrive at an accurate evaluation of Engine settling, centrifuging, heating and filtration before operating conditions and recommendations for it is injected into the combustion chamber.

10 The action. fuel injected therefore differs from the fuel delivered. - See Fig 1. 70. 60. 50 Fuel Analysis comparison 40. 30. 20. 10. 0. Sul V NA AL SI FE NI CA PB ZN P. Bunkers 55 16 9. Before Purifier 65 15 15 7 7 22 2 1 1 1. ME Rail 63 19 11 5 7 20 5 1 1 1. Figure 1 - comparison of Bunker Delivery Analysis with Analyses at Purifier and Fuel Pump The Engine The ability of the fuel to burn completely in the time available and produce energy to drive the Engine is dependent not only on the physical properties of the fuel but also on the design characteristics, the Engine settings and maintenance condition of the Engine . The Lubricant Cylinder lubricant is injected into each Cylinder to provide a uniform film of lubricant on the liner wall.